soft seated butterfly valves - airpower gmbh · 2017-06-14 · soft seated butterfly valves...
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Installation & Maintenance Instructions
Soft seated butterfly valves
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Original
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1.Installation in the pipeline
1.1 General remarks:
With the installation of the valves in a pipeline the same
instructions apply as to the connection of pipes and similar
piping elements. The following instructions additionally apply
to valves. For the installation site please also observe section
1.2.
With APE-Valves no separate flange
seals must be used: the elastic body
lining features integrated sealing
beads, which seal on the sealing strips
of the counterflanges. Counterflanges
must feature smooth sealing strips e.g.
blank flanges in accordance with the
EN 1092-1 Type 11 with packing strip in
according figure B1 or E2 or EN1759-1
Type 11 with packing strip according
figure B or E. Other flange shapes are
to be agreed on with the manufacturer,
Airpower europe GmbH.
The actuator is adjusted for the operat-
ing data stated in the order: The setting
of the end stops “OPEN” and
“CLOSED” must not be altered without
the consent of the manufacturer,
Airpower europe GmbH.
If - in an exceptional case - a valve has
to be mounted without actuator, it has
to be ensured that such a valve is not
pressurized. If an actuation unit is
retrofitted, torque, direction of rotation,
actuating angle and the setting of the
end stops “OPEN” and “CLOSED”
have to be agreed on with the manufac-
turer, Airpower europe GmbH. The non
-compliance of these instructions
might involve danger to the user and
cause damage to the pipe system.
Valves with electric actuator: APE-
Valves have to be shut off in a direc-
tion-dependent manner in both end
positions. The signals when the torque
switch responds are to be used for the
“fault” message. For further notes
please refer to the manual for the
electric actuator.
1.2 Working steps:
• Transport valve in the protective packaging to the
installation site and unpack it only there.
• Inspect valve and actuator for damage in transport.
Damaged valves or actuators must not be in-
stalled.
• Make sure that only valves are installed the pres-
sure class, connection type and connection
dimensions of which meet the application require-
ments. See name plate on the valve. The connec-
tion data for the actuator have to correspond to
the data of the control. See name plate on the
actuator.
The name plate or signs on the valve have still to
be identifiable after commissioning.
No valve must be operated above the
permissible pressure/ temperature range
of which is insufficient for the operating
condition. The non - compliance of this
instruction involves a risk to life and limb
and may cause damage to the pipe sys-
tem.
• The counterflanges have to feature a clear span
allowing for sufficient space for the opened valve
disc so that the latter is not damaged when being
swivelled out.
• Prior to installation the valve and the downstream
pipeline should be thoroughly cleaned of any
contamination, especially of hard foreign sub-
stances.
• APE-Valves can generally be installed irrespective
of the flow direction: however, from DN 250
onwards they are preferably to be installed with
horizontal shaft.
With solids-bearing media it is strongly
recommended to install the butterfly valve
in any case with horizontal shaft. If the
solids from deposits, the butterfly valve is
to be installed in such a way that the
bottom disc half opens in flow direction.
Installation
airpower europe GmbH Maarweg 30 D-53619 Rheinbreitbach T. +49(0)2224/988320 F. +49(0)2224 / 9883219 [email protected] www.airpower-gmbh.com
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• When inserting the valve (and the flange seals) in
an already mounted pipeline the distance between
the pipe ends has to be positioned in such a way
that all connecting surfaces and the elastic body
lining remain undamaged. The gap, however,
should not be larger than necessary so that no
additional stress is generated in the pipeline
during installation.
The valves have to be mounted with a
closed valve disc in the gap between the
pipe ends: otherwise the valve disc could
be damaged and the valve could leak.
(Figure 1)
Butterfly valves with actuator “safety
position OPEN”; For the installation in an
existing pipeline the opened valve disc
has to be closed with control medium and
inserted into the line and screwed on in a
completely closed state. Ensure that for
the duration of the installation process a
supply with control medium is available
with full control pressure for the closing
of the butterfly valve.
If this is not possible, a part of the pipe-
line has to be removed so that the valve
can be installed in opened position. The
non - compliance of this instruction could
cause injury.
• The counterflanges of the pipeline have to be
flush, level and parallel.
• Screws which are used in threaded holes of the
valve housing are to be implemented with a
separating agent (e.g. graphite-containing).
Check for stability of elastomer
• Flanged butterfly valves are to be centered on the
counterflange during installation by means of the
flange screws before the screws are tightened.
(Figure 2)
APE - valves partly require screws of a
varying length for the connection to the
counterflanges. (data sheet screws)
Installation
• The flange screws have to be tightened diago-
nally. With metal flanges the body of the butter-
fly valve must fit to the sealing strips of the
counterflanges with proper contact all round.
(Figure 3)
• In the case of plastic line systems with FRP
flanges the torque limit values of the respective
pipe and flange manufacturers are to be ob-
served for the tightening of the flange screws.
• With the connection of the actuator to the
control
the actuator manual manufacturer applies.
• At the end of the installation an operational
check with the signals of the control should be
carried out: the valve has to close and open
properly according to the control commands.
Discernible malfunctions are absolutely to be
redressed prior to commissioning.
Wrongly executed control commands
can be hazardous.
Correct
Disc positioned in the almost closed position. Pipe flange spread allows suffi-cient room for valve.
Figure 1 Initial Installation of Valve
Incorrect
Disc opened beyond valve body face. Pipe flanges not spread sufficiently.
airpower europe GmbH Maarweg 30 D-53619 Rheinbreitbach T. +49(0)2224/988320 F. +49(0)2224 / 9883219 [email protected] www.airpower-gmbh.com
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Figure 2 Centering and Flanging of Valve
Installation Recomendations
Figure 3 Flange Bolt Tightening Sequence
Figure 4 Final Valve Alignment and Tightening of Flange Bolts
Incorrect
Pipe Flanges misaligned. Uneven torque applied to bolting
Correct
Piping aligned. Thread engagement even on both sides of the valve.
Incorrect
Disc in closed position. Gaskets installed between valve and mating flanges
Correct
No flange gaskets used. Disc in the “almost closed”
Gasket
airpower europe GmbH Maarweg 30 D-53619 Rheinbreitbach T. +49(0)2224/988320 F. +49(0)2224 / 9883219 [email protected] www.airpower-gmbh.com
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Correct
Open pipework flanges to allow entry of valve without rubbing against the seat. Rotate valve handle or actuator to position disc about 1/4“ from the outside edge of the seat (as shown). This will project disc edge from bumping pipework, and reduce seat interference and initial torque build-up.
Incorrect
DO NOT try to install valve with pipework flanges spread insufficiently. This will damage the valve seat and prevent the valve from operating properly. DO NOT install valve with disc in open position (as shown), or disc will impact pipework flanges and damage polished sealing edge of disc.
Correct
Position the valve between pipework flanges and assemble the valve housing to the flanges, using all required flange bolts. DO NOT USE ANY TYPE OF FLANGE GASKETS. The O-ring sealing section of the butterfly valve seat provides a positive seal to all popular flanges.
Incorrect
DO NOT try to install the valve with the disc fully closed. Remove actuator if necessary, to allow slight opening of disc. Installation with disc fully closed will cause seat distortion because of seat rubber trying to close around disc edge (as shown). This installation will cause exces-sive torque in initial operation.
Correct
Turn the valve disc to the full open position. Center the valve housing in the flanges, and hand-tighten bolts. Slowly close the valve to check for clearance between valve disc and pipe or Flange I.D. If valve disc hits, reposition valve as necessary. Reopen valve disc to full open position and cross tighten all bolts to proper torque specification.
Incorrect
DO NOT misalign valve housing or pipe-work (as shown). Misalignment may cause interference between disc edge and flange face. This will result in leakage, excessive torque and possible damage to disc and seat. Operation of valve in misaligned flanges may also create a pocket where flowing media may come entrapped.
Maintenance Instructins
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Flange Bolting Recommendations
DN PN Menge Quantity
Sechskantschraube nach DIN 933(Zwischenflansch) For Wafer Bodies Bolt with
Nut Thread
Länge Length
(mm/inch)
Menge Quantity
Sechskantschraube nach DIN 933 (Anflansch)
For Lug Bodies with Nut Thread
Länge Length
(mm/inch) Inch
50
PN10 4 M16 145 4x2 M16 40
2“ PN16 4 M16 145 4x2 M16 40
ANSI150 4 5/8“ - 11 UNC 130 4x2 5/8“ - 11 UNC 40
65
PN10 4 M16 150 4x2 M16 40
2,5“ PN16 4 M16 150 4x2 M16 40
ANSI150 4 5/8“ - 11 UNC 140 4x2 5/8“ - 11 UNC 45
80
PN10 8 M16 150 8x2 M16 40
3“ PN16 8 M16 150 8x2 M16 40
ANSI150 4 5/8“ - 11 UNC 145 4x2 5/8“ - 11 UNC 45
100
PN10 8 M16 160 8x2 M16 45
4“ PN16 8 M16 165 8x2 M16 45
ANSI150 8 5/8 150 8x2 5/8“ 45
125
PN10 8 M16 165 8x2 M16 50
5“ PN16 8 M16 170 8x2 M16 50
ANSI150 8 3/4“ - 10 UNC 155 8x2 3/4“ - 10 UNC 50
150
PN10 8 M20 175 8x2 M20 50
6“ PN16 8 M20 180 8x2 M20 50
ANSI150 8 3/4“ - 10 UNC 160 8x2 3/4“ - 10 UNC 50
200
PN10 8 M20 180 8x2 M20 55
8“ PN16 12 M20 185 12x2 M20 55
ANSI150 8 3/4“ - 10 UNC 170 8x2 3/4“ - 10 UNC 55
250
PN10 12 M20 200 12x2 M20 60
10“ PN16 12 M24 210 12x2 M24 60
ANSI150 12 7/8“ - 9 UNC 190 12x2 7/8“ - 9 UNC 60
PN10 12 M20 210 12x2 M20 65
300 12“ PN16 12 M24 230 12x2 M24 65
ANSI150 12 7/8“ - 9 UNC 200 12x2 7/8“ - 9 UNC 60
350
PN10 16 M20 215 16x2 M20 65
14“ PN16 16 M24 240 16x2 M24 65
ANSI150 12 1“ - 8 UNC 220 12x2 1“ - 8 UNC 65
400
PN10 16 M24 255 16x2 M24 75
16“ PN16 16 M27 280 16x2 M27 75
ANSI150 16 1“ - 8 UNC 245 16x2 1“ - 8 UNC 80
Installation for Series 23 and 24
airpower europe GmbH Maarweg 30 D-53619 Rheinbreitbach T. +49(0)2224/988320 F. +49(0)2224 / 9883219 [email protected] www.airpower-gmbh.com
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Flange Bolting Recommendations
DN Inch PN Menge Quantity
Sechskantschraube nach DIN 933(Zwischenflansch) For Wafer Bodies Bolt with
Nut Thread
Länge Length
(mm/inch)
Menge Quantity
Sechskantschraube nach DIN 933 (Anflansch)
For Lug Bodies with Nut Thread
Länge Length
(mm/inch)
450 18“
PN10 20 M24 275 20x2 M24 80
PN16 20 M27 310 20x2 M27 80
ANSI150 16 1 1/8“ - 8UN 265 16x2 1 1/8“ - 8UN 80
500 20“
PN10 20 M24 295 20x2 M24 85
PN16 20 M30 335 20x2 M30 90
ANSI150 20 1 1/8“ - 8 UN 285 20x2 1 1/8“ - 8 UN 90
600 24“
PN10 20 M27 340 20x2 M27 100
PN16 20 M33 385 20x2 M33 100
ANSI150 20 1 1/4“ - 8 UN 312 20x2 1 1/4“ - 8 UN 110
700 28“
PN10 24 M27 355 24x2 M27 100
PN16 24 M33 400 24x2 M33 100
ANSI150 28 11/4“ 385 28x2 11/4“ 130
800 32“
PN10 24 M30 395 24x2 M30 120
PN16 24 M36 460 24x2 M36 120
ANSI150 28 11/2“ 435 28x2 11/2“ 140
900 36“
PN10 28 M30 425 28x2 M30 130
PN16 28 M36 490 28x2 M36 130
ANSI150 32 11/2“ 470 32x2 1 1/2“ 160
1000 40“
PN10 28 M33 465 28x2 M33 140
PN16 M39 535 28x2 M39 140
ANSI150 36 11/2“ 480 36x2 1 1/2“ 160
1200 48“
PN10 32 M36 535 32x2 M36 160
PN16 32 M45 485 32x2 M45 100
ANSI150 44 1 1/2“ 555 44x2 1 1/2“ 180
1300 52“
PN10
PN16
ANSI150 44 1 3/4“ 600 44x2 1 3/4“ 190
1400 56“
PN10 36 M39 480 36x2 M39 160
PN16 36 M45 525 36x2 M45 120
ANSI150 48 1 3/4“ 615 48x2 1 3/4“ 200
Installation for Series 23 and 24
airpower europe GmbH Maarweg 30 D-53619 Rheinbreitbach T. +49(0)2224/988320 F. +49(0)2224 / 9883219 [email protected] www.airpower-gmbh.com
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Installation for Series 40
Flange Bolting Recommendations
DN Inch PN Menge Quantity
Sechskantschraube nach DIN 933 (Doppel-Flansch) For Double-Flange Bodies
Bolt with Nut Thread
Länge Length
(mm/inch)
700 28“
PN10 24x2 M27 175
PN16 24x2 M33 220
ANSI150 28x2 1-1/4 195
800 32“
PN10 24x2 M30 185
PN16 24x2 M36 250
ANSI150 28x2 1-1/2 225
900 36“
PN10 28x2 M30 205
PN16 28x2 M36 270
ANSI150 32x2 1-1/2 245
1000 40“
PN10 28x2 M33 230
PN16 28x2 M39 300
ANSI150 36x2 1-1/2 245
1200 48“
PN10 32x2 M36 265
PN16 32x2 M45 230
ANSI150 44x2 1-1/2 280
1300 52“
PN10
PN16
ANSI150 44x2 1-3/4 300
1400 56“
PN10 36x2 M39 200
PN16 36x2 M45 240
ANSI150 48x2 1-3/4 315
airpower europe GmbH Maarweg 30 D-53619 Rheinbreitbach T. +49(0)2224/988320 F. +49(0)2224 / 9883219 [email protected] www.airpower-gmbh.com